Performance Problems and Structural Retrofit Analysis of Existing BCTs

Abstract

Automobile accident reports and full-scale crash tests of existing breakaway cable terminals (BCTs) indicated their poor performance during end-on impacts. This paper presents results of a feasibility study, which was conducted to identify problems with existing BCTs. The nonlinear, explicit, dynamic finite-element code LS-DYNA was used in the investigation of BCT design problems. Several problems were identified in the past during the full-scale crash tests. These problems became clearly visible when computational mechanics analyses were used. In addition to severe vehicle damage, vehicular impact induced dangerous, large deceleration peaks and uncontrolled vehicle trajectories. Analysis of actual crash tests and LS-DYNA data led to the conclusion that the terminal is too stiff along its longitudinal direction and fails to smoothly control dissipation of the vehicle kinetic energy. Therefore, the major objective of the research was to soften the existing system by weakening the rail in strategically located areas. The paper describes the design retrofit process, which was continuously guided by computational mechanics analyses. Specific retrofit recommendations emerged at the end of this process and they are described in the paper. Full-scale crash tests are recommended to confirm expected benefits of the proposed retrofit.